Method and apparatus for producing elastic knitted fabric



June 14, 1938.

H. K. LE A 2,120,758 METHOD AND APPARATUS FOR: PRODUCING ELASTIC KNITTED FABRIC Filed April 20; 1935 6*Sheet-Sheet 1 H. K. LEA

June 14, 1938.

METHOD AND APPARATUS FOR PRODUCING ELASTIC KNITTED FABRIC Filed April 20, 1935 6 Sheets-Shee t 2 .Jun e'14, 1938. H. K. LEA

METHOD AND APPARATUS FOR PRODUCING ELASTIC KNITTED FABRIC Filed April '20} 1935 6 Sheets-Sheet 3 Jime 14, 1938. H. LEA -v umnoo AND APPARATUS FOR PRODUCING ELASTIC KNITTED mama Fil ed Apr-11 20. 1955 e sheets-sheet 4 H. K. LEA 2,120,758 UCING ELASTIC KNITTED FABRIC mmnon AND APPARATU' FOR PROD Jun; 14

Filed April 20, 1935 s Sheets-Sheet 5 June 14, 1938.

H. K. LEA I 2,120,758 METHOD AND APPARATUS FOR PRODUCING ELASTIC KNITTED FABRIC Fileq April 20. {1935 e-sheets-sheet a flarvy JFLea.

Patented June 14, 1938 UNITED? STATES ran-mop AND APPARATUS FOBIBODUCIN ms'nc KNITTED FABRIC I llal'ryLImJmmN.Y.,aIign0rtoKcnlea lanafactarlng Corps Johnstown. N. I.

am April so, 1935, Serial No. 11,521 claims. (Cl. 91-8) 'niis invention relates to a method and apparatus for producing elastic knitted fabric. of the type disclosed inapplicationiiled by Harry K. Lea, on March 28th, 1935, Serial Number 13,576 and the spreader blade or knifeforming a part of the apparatus is shown in detail in application flledby HarryK.1ea,onMarch28th, 1935, Serial Number 13,575. Various methods and machines are known and m are in use for the coating of woven fabric with a rubber cement or adhesive for the production of an elastic woven fabric, but in view of the flimsy character and stretching characteristics of knitted fabrics, such a jersey silk and the like,

15 it has heretofore been impossible to handle knitted fabrics and effect an even distribution of adhesive or rubber cement coating thereon as the knitted fabric has a tendency of unduly stretching and rolling during the coating opera- 20 tion and it has heretofore been commercially impossible to produce a coated knitted fabric of the type dmclosed in the aforesaid applications.

It is therefore the primary object of this invention to provide apparatus and a novel method for the coating and flocking of a knitted fabric, such as jersey silk or the like with the resultant fabric possessing its basic inherent stretching characteristics with increased elasticity imparted thereto by the rubber cement coating as com- 30 pared with similarly coated woven fabrics, the flocking material presenting a soft velvety finish on one face of the knitted fabric witi 'the other fa: thereof possessing the original characteris- A further object of the invention is to provide an apparatus of the foregoing character for the production of an elastic knitted fabric and embodying devices fbr applying an adhesive or rubber cement coating to one face of the fabric, 40 appying comminuted flbre such as flocking ma terial to the adhesive coatin drying the coating and then forming minute perforations completely through the coated fabric, while the adhesive coating is in a dry and plastic condition and 45 thereafter vulcaniaing the coated fabric with the walls of the minute perforations maintaining their spaced relation for the purpose of ventila-' tion or breathing when the elastic knitted fabric is used in the manufacture of corsets, girdles, 5 hrassieres, or the like.

The method disclosed in this application comprises several steps of treating a knitted fabric, such as jersey silk, by applying and spreading an adhesive or rubber cement coating onto one face 5 thereof, applyi g comminuted flbres or flocking -material to the adhesive coating, exhausting fumes or gases emanating from the adhesive coating, drying the coating, forming minute perforations through the fabric and then vulcanizing the coated fabric and thereafter batchingthe same 5 onto a roll.

With the above and other objects in view that will become apparent as the nature of the inven tion' is better understood, the same consists in the novel form, combination and arrangement of parts hereinafter more fully described, shown in the accompanying ,drawings and claimed.

In the drawings:-- 7

Figures 1, 1A and 1B, are match lines side elevational views,'partly in section of the complete apparatus, showing the device for applying a coating or adhesive cement to the knitted fabric, the device for applying flocking material to the adhesive coating, the means for exhausting fumes from the adhesive coating. the drying device, per- -forating device for the coated fabric, a part of the operating mechanism and the batching means; t

Figures 2, 2A nd 23, are match line'opposlte side elevational 'views of the apparatus, partly broken away and illustrating the driving mechanism, the fumes exhauster for the flocking mechanism;

Figure 3 is a fragmentary side-elevations] view I of the endless apron carrying the coated knitted fabric through the flocking mechanism with the I beater bars for the apron to effect spreading of the flocking-material illustrated in cross section I as of polygonal formation;

Figure 4 is a plan view-of one of the screened flock receptacles; v Figure 5 is a vertical cross sectional view taken on line 5-5 of Figure 2A, showing the motor operated blower for exhausting fumes from the adhesively coated fabric; 40

Figure 6 is a detail sectional view showing the rotary brush for removing excess flocking material from the coated fabric and the pin and coopcrating roller for forming minute openings in the coated knitted fabric prior to vulcanization of the fabric;

Figure 7 is a side elevational view of the pin roller and cooperating roller with the flocked and coated fabric passing therebetween shown in section; 5

Figure 8 is a fragmentary side elevational view showing the batching roller receiving the coated fabric after being perforated; and

Figure 9 is a fragmentary side elevational view of a modified construction, showing the fabric mg the adhesive apply a rubber cement or adhesive coating to such knitted fabrics and to effect an even distribution and adhesive coating thereon because knitted fabrics when passed through a coating machine are subjected to pulling and stretching strain which results in wrinkling and rolling of the fabric. The first step of the method practiced by the apparatus disclosed herein is to stiffen or size opposite side edges of the stripof knitted fabric, the line of greatest stretch being between the sized edges and then winding the strip of knitted fabric onto a roll shown at ID in Figure 1. The apparatus disclosed herein will be described by following the path of travel of the fabric strip II from the roll 10, particular reference being had to Figures 1, 1A and 1B.

The knitted fabric strip I l first passes to the adhesive supply and spreading device designated in general by the reference character I2 and shown in detail in application filed by Harry K. Lea, on March 28th, 1935, Serial No. 13,575 and briefly referred to herein comprises a stand l3 including a stationary cylinder l4 over which the fabric strip ll passes, the rubber cement or adhesive being fed onto the stripabove the cylinder I 4 from the regulable hopper I5 and spread over the fabric strip by means of the spreader blade or knife l6 vertically adjustable in the stand I3. A longitudinal groove 11 is formed in the upper side of the cylinder l4 in line with the spreader knife I6 to prevent contact of the spreader knife with the fabric strip and to permit flexure of the fabric strip in passing over the cylinder l4 for the more effective even distribution of the adhesive coating without forccoating into the interstices of the knitted fabric, the coating being merely laid onto the knitted fabric, but tenaciously adhering thereto and ultimately becoming an immovable integral part of the knitted fabric.

The fabric strip II with the adhesive coating thereon then passes through the flocking mechanism shown more clearly in Figures- 1, 3 and 4 and said fabric strip before its entry into the flocking mechanism has the opposite sized edges thereof engaged with tenter frames such as shown in the patent to C. Von Glahn for Paper feeding apparatus, Patent No. 977,146, dated November 29, 1910 which comprises an endless conveyor at each side of the fabric strip, the endless conveyors having parallel runs I 8 with clips for the sized edges of the fabric strip that are automatically operated for opening movement -to release the strip after passage through the apparatus and for closing movement to engage the strip to feed the same through the apparatus such tenter frames being common to the art of treating fabric and specifically not forming a part of the present invention. The support for the forward ends of the tenter frames comprises a stand I9 and frame structures 20. An endless apron 2| passes over a guide roller 22 in the stand l3 adjacent the cylinder l4 and the horizontal run of the apron 2| extends over the supporting roller 23 beyond the flocking "mechanism, the endless apron 2| being trained over a slack adjuster cylinder 24 supported on the stand l9 by means of the bracket I So and is adjustable as shown at 24a with the apron 2| driven by mechanism to be Eater described. A pair of casings 25 is supported on the upper run of the endless apron 2|.

the frame structures 20 above the tenter frames l8 and each casing 25 has a screened flock receptacle 28 shown in detail in Figure 4 journalled therein by means of the shaft ends 21 journalled in the bearings 28. One shaft end carries a pulley 29 disposed exteriorly of the casing 25 for association with a drive belt to be later described. The screened receptacles or sifters 26 are preferably of polygonal formation in cross section and particularly hexagonal to aid in diffusion of the comminuted fibres thereon for more-effective sifting of the flocking material therefrom. Each casing 25 has a sliding drawer or plate 3!] disposed therein beneath the screened receptacle 26 whereby either or both screened receptacles may be employed in the flock coating step of the method. To effect a complete application of the flocking material to the adhesive coating, a plurality of beater bars 3| is journaled on the frame structure 20 and extend transversely of and beneath The beater bars 3| are of polygonal form in cross section as illustrated in Figure 3 with the corners thereof successively moved into contact with the apron to effect vibration thereof and vibration of the coated fabric strip l I carried by the apron 2| through the flocking'devices.

After the fabric strip II has been coated with the rubber cement or adhesive and flocking material, the same is carried by the tenter frames and endless conveyors through a, casing 32 having heating devices 33 therein to effect drying of the adhesive. The section of the casing 32 illustrated in Figures 1A, 2A and 5, has blowers and exhaust means associated therewith for carrying off the fumes from the adhesive coating. An electric motor 34 has a belt connection 35 with a blower 36 communicating with a manifold 31 exteriorly of the casing 32 with branch nozzles 38 in the manifold 31 extending transversely within the casing 32 beneath the heating devices 33 for blowing air upwardly through the casing and over the fabric strip I l with the fumes conveyed to the hood 39 carried by the top wall of the casing 32 with pipe extensions 40 from the hood leading to outlets or exhaust conduits 4i.

The fabric strip ll continues in its travel through the casing section 32 shown in Figure 1B and upon passage from the casing section 32, the fabric strip coated with adhesive and fiocking'material is engaged by a combination rotary brush and flock exhausting device and a pin roller for forming minute openings in the fabric strip. As shown in Figures 1B, 6 and 8, the flocked face of the fabric strip II is engaged by a rotatable brush 42 after leaving the casing 32 for the removal of excess flocking material from the fabric and said rotary brush 42 is confined in a hood 43 that is in communication with a conduit 44 that leads to a suction device 45, that in turn is in communication I with a receptacle of any character.

When the coated fabric strip leaves the casing 32 and passes the brush 42, the same is in a substantially dry condition with practically all moisture removed from the adhesive coating, the fabric strip ll then passing between a pin roller 46 having its entire peripheral surface studded with radial pins and a cooperating cushis trained over a guide roller ll for reception on a batching roller 45 rotated by a driven roller 5| supported in the rack frame 5|.

Reference will now be made to Figs. 2, 2 and 2B which are opposite side elevational views" of the apparatus and more clearly disclose the operating devices for the movable part of the mechanism. As shown in Figure 23, each pulley 29 of a screened flock sifter 25 has a belt connection 52 with pulleys 53 and said pulleys 53 are connected by a belt 54. One of the pulleys -53 has a belt connection 55 with an electric motor 55. Corresponding ends of the beater bars 3| carry pulleys 51 and alternate ones of said beater bars associated with the flock sifter adjacent the electric motor 56 carry additional pulleys 58 and 59 respectively. A belt connection 60 extends between the pulley 58 and a pulley 6| supported on the shaft carrying the pulley 53 while a belt 52 connects the pulley 59 to the adjacent pulley of the next flocking device.- Belts 83 form communication between the several pulleys 51 of each flocking device. It. will therefore be seen that the electric motor 55 effects the rotation of the flock sifters 26 and rotation of the beater bars 3|. The roller 23 over which the apron passes has a gear connection with the tenter frames whereby the apron travels at the same speed as the tenter frames. As shown in Figures 13 and 2, the shaft of the electric motor 66 has a belt connection 51 with a pulley 68' fixed to the shaft 69 and said shaft 59 carries a worm l0 engaged with a wormwheel II. The shaft 12 carrying the worm wheel 1| also has a bevel gear 13 that meshes with a bevel gear 14 that is operatively engaged with the endless conveyor of a tenter frame, a duplicate drive being provided for each tenter frame. The shaft 12 carries a sprocket wheel I5 that has a sprocket chain connection 16 for the sprocket wheel TI fixed to the shaft supporting the driving roll 50 for the batching roller 49. A belt connection 18 forms communication between the shaft 12 and shaft carrying the pushioned roller 41 associated with the pin roll 45 to effect positive drive of the pin roller by the pins on the peripheral surface thereof passing through the coated fabric and engaging the cushioned roller, the tension of the pin roll being regulated by the hand lever 19 and appurtenant part illustrated in Figures 1B and 2.

The operating means for the rotary brush 4! that removes excess flocking material from the coated knitted fabric comprises an electric motor I. having a belt connection 8| with the pulley 82 on the shaft 83 carrying the rotary brush. Another pulley 54 fixed to the shaft 83 has a belt connection 85 with a pulley 85 carried by the'shaft of thev suction producing device 45. Devices are provided for relatively adjusting the two tenter frames between which the strip of fabric is positioned for movement through the apparatus and to accommodate the-apparatus to fabric strips of different widths, such devices being briefly illustrated in Figures 113 and 2 as comprising a shaft 81 extending longitudinally of the apparatus with bevel gears I. thereon that mesh with bevel gears 59 on cross shafts '55 operated by hand wheels 9!, shown in Figure 1, the cross shafts 5| being operatively engaged with the tenter frames for effecting movements thereof towards and away from each other, these devices forming no material part of the present invention. r

In the apparatus shown in Figures 2 and 8,'th

coated fabric after leaving the pin roll 46 is received on the batching roll 49 and vulcanization thereof is subsequently accomplished. As shown in Figure 9, the apparatus includes a modified step in the method of vulcanizing the perforated coated fabric after leaving the pin roll and prior' to reception on the batching roll. The end section 32a of the casing has the heater elements 33a. arranged adjacent the bottom thereof and the fabric strip Ha having been coated with rubber 'cement or adhesive and covered with flocking material and then passed over the pin roll '45 as previously described, itis then re-directed through the casing 32a as shown at lib and guided in such movement by the roller supports 92 to accomplish vulcanization thereof before reception on the batching roller 49.

From the above detailed description of the invention, it is believed that the constructionand operation thereof will at once be apparent and while there are herein shown, and described the preferred embodiments of the invention, it is nevertheless to be understood that minor changes may be made therein without departing from the spirit and scope of the invention as claimed.

I claim 1. Apparatus for producing elastic fabrics wherein the longitudinal side edges of the base material from which the elastic fabric is produced means for applying flocking material to the rub-'- her cement, and means for feeding the'base material through the apparatus for action by all of said means including endless carriers having means engaged with the sized edges. of the base material to hold the same transversely taut and in the absence of longitudinal stretching tension, the flock applying means including screened cylinders rotatable above the line of travel of the base material, a casing structure supporting each cylinder, and means in the casing structure beneath the cylinder for controlling the feed of flocking material.

2. Apparatus for producing elastic fabrics wherein the longitudinalside edges of the base material from which the elastic fabric is produced have been sized, wherein a rubber cement is applied to one face of the base material, and wherein a flocking material is applied to the rubber cement, means for perforating the base material, means for feeding the coated base material through the apparatus including endless carriers having means engaged with the sized edges of the base material to hold the same transversely taut and the said means for perforating the coated base material comprising a rotatable cylinder with a cushioned periphery and a cooperating rotatable'cylinder having pins projecting peripherally therefrom with the coated base material passing between the cylinders.

3. The method of producing an elastic fabric froma base material and of a composite type having its opposite sides presenting faces differing in appearance with the material of the opposite faces individual to the zone of such face and with the material of one of the face zones free from interconnection with that of the other, said method consisting of first sizing the longitudinal edges of the base material to prevent rolling and stretching'of the base material during treatment thereof, applying an adhesive coating to one face of the base material and then applying flockingof knitted base material and of a composite type having its opposite sides-presenting faces diflering' in appearance with-the material of the opposite faces individual to the zone of such face and with the material of one of the face zones free from interconnection with that of the other, said method consisting of first sizing the longitudinal edges of the knitted jersey to prevent rolling and stretching of the knitted jersey during treatment thereof, gripping the sized edges of the knitted jersey for movement through the treating apparatus therefor with the knitted jersey maintained in a smooth condition, then applying an adhesive coating to one face of the knitted jersey, then applying a flocking material to the adhesive coat: ing and then vulcanizing the coated knitted jersey.

- 5. Apparatus for producing elastic fabrics ineluding means for applying a rubber cement to one face of the base material trom which the elastic fabric is produced, means for applying flocking material to the rubber cement and means for feeding the base material through the apparatus for action by all of said means including endless carriers having means engaged with the edges 01' the base material to hold the same transe versely taut and in the absence of longitudinal stretching tension, the flock applying means including screened cylinders rotatable above the line of travel 01 the base material, a casing structure supporting each cylinder and means in the casing beneath the cylinder for controlling the feed of flocking material.

' HARRY K. LEA. 

